Kinematic link vehicle

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CONTENTS

---------------------------------------------------------------------------------SYNOPSIS

KYNAMATIC LINK VEHICLE

SYNOPSIS

Mechanical Engineering without production and manufacturing is meaningless and inseparable. Production and manufacturing process deals with conversion of raw materials inputs to finished products as per required dimensions, specification and efficiently using recent technology. The new developments and requirements inspired us to think of new improvements in air conditioning Engine ering field. Nowadays air cooler is available in market.

In our project, The power is used to run the air blower when ever we required. ABSTRACT A project is an endeavor to carry out some specific purpose. As we know wheel driven vehicle can move on plane surface and belt driven vehicle can move on the critical surface. but this vehicle cannot be move on to uneven surface ,pond, or on in the river they cannot be functional, they. But this is a vehicle which can move on any rough surface as well as on to uneven surface. This vehicle is moves on to surface by means of high pressure power gap. A high torque e in to the bottom surface which bears as an lifting serve as a friction less bearing.The movement is controlled by the motor direction propeller which controls direction And reverse forward motion through the motor speed. To control the operation an wire control system is used.

INTRODUCTION

2.1.1 PowerMany robots are battery powered. Well tackle power considerations later but should mention it here. To save power, the following features must be enrolled: Lower-voltage electronics Low-power operation Support in the operating software for low-power states Lower-frequency operation Petrol powered engine

2.1.2 Battery:Commonly batteries are available in 6 and 12 and 24 volts rating. Other than the voltage rating, the Ampere-Hour (AH) rating is used to define the power availability or capacity of the battery.The backup time provided by a battery connected to inverter depends on the DC bus voltage of the inverter. This depends on their design. It could be 24V, 48V, 72V, 120V so on. Normally more than one 6volt or 12volts battery is used in series for higher voltage requirement. For example, if 48V battery is required with an inverter, then four 12V batteries can be connected in series to provide 48V supply.

MotorsEach joint in a stationary robot needs a motor to make it move back and forwards. Another name for a motor is an actuator. These motors can be powered by electricity, compressed air (pneumatics), or pressurized liquid. In mobile robots, motors are linked to each wheel, track or leg. By controlling the direction of rotation of a wheel, the robot can be turned and steered in a chosen direction. We are using DC motor as actuation for the vehicle. These are DC geared motor so that more torque can be delivered by the motor.

BLOCK DIAGRAM

legs

SWITCHSWITCHMotor POWER Motor

WORKING PRINCIPLEMotor power is used to run the blade and legs . Block diagram,The motor is coupled with impeller legs. The motor runs during the air ON, the impeller rod starts rotating. The chain drive is used to circulate the unit.

The forced power is flow through the chain which is moved by legs assembly, so that the weight lift is produced.

ADVANTAGES

Simple in construction This system is noise in operation It is portable, so it can be transferred easily from one place to other place Maintenance cost is low

DISADVANTAGES

It does not take turn Initial cost is high

APPLICATION

The kynamatic link vehicle is used in Home Industries Agricultural sparing By adding control circuit, we can maintain the kynamatic link vehicle for military use

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CHAPTER-1

INTRODUCTION

AIR ENERGY

INTRODUCTION:

AbstractA short tutorial on Homogeneous Transforms is presented covering the tripleinterpretation of a homogeneous transform as an operator, a coordinate frame,and a coordinate transform. The operator / transform duality is derived and itsuse in the Denavit Hartenberg convention is explained. Forward, inverse, anddifferential kinematics are derived for a simple manipulator to illustrate concepts.A standard set of coordinate frames is proposed for wheeled mobile robots. It isshown that the RPY transform serves the same purpose as the DH matrix in thiscase. It serves to interface with vehicle position estimation systems of all kinds,to control and model pan/tilt mechanisms and stabilized platforms, and to modelthe rigid transforms from place to place on the vehicle. Forward and inversekinematics and the Euler angle rate to the angular velocity transform are derivedfor the RPY transform.Projective kinematics for ideal video cameras and laser rangefinders, and theimaging Jacobian relating world space and image space is derived. Finally, thekinematics of the Ackerman steer vehicle is presented for reference purposes.This report is both a tutorial and a reference for the transforms used in theRANGER vehicle controller. It is both because the models keep evolving and itwas necessary to provide the tools, mechanisms, and discipline required to continuethe evolution.

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CHAPTER-2

CONSTRUCTION AND WORKING

2.1 PRINCIPLE OF WORKING:

The motor is made to rotate by using a battery . The supply of the current is been given from the 12 V battery provided.

The panel board is fixed by providing the M.S. flots. The rotating motor can be adjusted to any motion of angle by a tilting mechanism. The leg is made to rotate by providing a bearing. Battery for the storage provision. The stored energy from battery is supplied to the motor for operating the vehicle. The discharge of the electrical energy from the battery will be equal to the charging of the battery.The whight transfer and shift is originated by the kinematic link shift and the shape of the crank mechanism . the assembly is equipped by the pick and place robot to operate any additional functionality. The separated motor are attached to the arm to execute the different movement by controlling motor control swich board.the battery and the unit is connted by the cables. The weight of vehicle body and battery is lifted by the equal motor. The all mtotro is dc type geared so high torque is obtained.

2. 4. 4. DC motor :

PRINCIPLE OF OPERATION:

The basic principle of motor action lies in a simple sketch. The working principle tells that, when a current carrying conductor is placed in a magnetic field, a force is produced to move the conductor away from the magnetic field.

Movement ofConductor

SN

Magnetic flux Current carrying Conductor

The force given by the equation,

F=B I L NewtonsWhere,B = Flux density in WB/sq.mI = Current through the conductorL = Length of the conductor

Let us consider a single turn coil. The coil side A will be forced to move downward, where as the coil side B will be forced to move upward. Due to this movement now the coil is made to rotate. Since the coil is arranged into rotate. Since the coil is arranged in the armature when it rotates in emf is induced in the coil and that emf which is induced in the coil is in opposite to supply emf. Therefore we can call the emf induced as back emf (B-emf). Hence when motor runs normally the supply emf (V) is equal to B-emf.Therefore V = Vb + Va (or) V = Vb + Ia Ra (Since V= IR)Multiplying both sides by Ia,Therefore Via = Vb Ia + (Ia x Ia) RaWhere Via is the electrical equivalent of the mechanical power developed in the motor and (Ia x Ia) Ra is armature drop.This process that motor converts electrical energy mechanical energy where (Ia x Ia) Ra is the copper loss which is to be neglected.

2. 4. 5. BATTERY:LEAD ACID BATTERY:The positive and negative electrodes of a lead acid battery are immersed in dilute sulphuric acid. When the battery is fully charged, there is lead peroxide an the positive plate and spongy lead on the negative plate as the active materials. During the process of discharge, the chemical reactions from lead sulphate on both the plates thereby, liberating water. The specific gravity of the electrolyte is lowered during charging, there is reversal of the chemical reaction and the specific gravity of the electrolyte rises. The specific gravity is a good indication of the state of charge of a battery. The chemical reactions that take place during charging and discharging are as follows.

ChargedDischarged

PositiveElectrolyteNegative PositiveElectrolyteNegativePlatePlatePlatePlate

Pbo + 2H SO+ pb==== pbso + 2H O + pbso

(Lead(Sulphuric(Spongy(Lead(Water)(LeadPeroxide) acid) lead) sulphate) sulphate)

From the above equation, it is evident that the discharge is carried to the last point. However, in practice, the battery is never charged beyond a certain point because of two reasons. First, lead sulphate occupies a greater volume that lead peroxide and hence excessive sulphation is liable to setup mechanical stresses in the positive plates, thereby causing shedding of active material and tracking of the plates. Secondly, the excessive sulphation does not permit the sulphate to get reconverted fully back to the active material during chargingCHEMICAL ACTION:

Sulfuric acid is a combination of hydrogen and sulfate ions. When the cell discharges, lead peroxide from the positive electrode combines with hydrogen ions to form water and with sulfate ions to form lead sulfate.

Combining lead on the negative plate with sulfate ions also produces he sulfate. There fore, the net result of discharge is to produce more water, which dilutes the electrolyte, and to form lead sulfate on the plates.As the discharge continues, the sulfate fills the pores of the grids, retarding circulation of acid in the active material. Lead sulfate is the powder often seen on the outside terminals of old batteries. When the combination of weak electrolyte and sulfating on the plate lowers the output of the battery, charging is necessary.On charge, the external D.C. source reverses the current in the battery. The reversed direction of ions flows in the electrolyte result in a reversal of the chemical reactions. Now the lead sulfates on the positive plate reactive with the water and sulfate ions to produce lead peroxide and sulfuric acid. This action re-forms the positive plates and makes the electrolyte stronger by adding sulfuric acid. At the same time, charging enables the lead sulfate on the negative plate to react with hydrogen ions; this also forms sulfuric acid while reforming lead on the negative plate to react with hydrogen ions; this also forms currents can restore the cell to full output, with lead peroxide on the positive plates, spongy lead on the negative plate, and the required concentration of sulfuric acid in the electrolyte.

The chemical equation for the lead-acid cell is

Charge

Pb + pbO + 2HSO 2pbSO + 2HO

Discharge

On discharge, the pb and pbo combine with the SO ions at the left side of the equation to form lead sulfate (pbSO) and water (HO) at the right side of the equation.

One battery consists of 6 cells, each have an output voltage of 2.1V, which are connected in series to get a voltage of 12V and the same 12V battery is connected in series, to get a 24 V battery. They are placed in the water proof iron casing box.

CARING FOR LEAD-ACID BATTERIES:

Always use extreme caution when handling batteries and electrolyte. Wear gloves, goggles and old clothes. Battery acid will burn skin and eyes and destroy cotton and wool clothing.

The quickest way of ruin lead-acid batteries is to discharge them deeply and leave them stand dead for an extended period of time. When they discharge, there is a chemical change in the positive plates of the battery. They change from lead oxide when charge out lead sulfate when discharged. If they remain in the lead Sulfate State for a few days, some part of the plate dose not returns to lead oxide when the battery is recharged. If the battery remains discharge longer, a greater amount of the positive plate will remain lead sulfate. The parts of the plates that become sulfate no longer store energy. Batteries that are deeply discharged, and then charged partially on a regular basis can fail in less then one year.

Check your batteries on a regular basis to be sure they are getting charged. Use a hydrometer to check the specific gravity of your lead acid batteries. If batteries are cycled very deeply and then recharged quickly, the specific gravity reading will be lower than it should because the electrolyte at the top of the battery may not have mixed with the charged electrolyte. Check the electrolyte level in the wet-cell batteries at the least four times a year and top each cell of with distilled water. Do not add water to discharged batteries. Electrolyte is absorbed when batteries are very discharged. If you add water at this time, and then recharge the battery, electrolyte will overflow and make a mess.

Keep the top of your batteries clean and check that cables are tight. Do not tighten or remove cables while charging or discharging. Any spark around batteries can cause a hydrogen explosion inside, and ruin one of the cells, and you.

On charge, with reverse current through the electrolyte, the chemical action is reversed. Then the pb ions from the lead sulfate on the right side of the equation re-form the lead and lead peroxide electrodes. Also the SO ions combine with H ions from the water to produce more sulfuric acid at the left side of the equation.

CURRENT RATINGS:

Lead-acid batteries are generally rated in terms of how much discharge currents they can supply for a specified period of time; the output voltage must be maintained above a minimum level, which is 1.5 to 1.8V per cell. A common rating is ampere-hours (A.h.) based on a specific discharge time, which is often 8h. Typical values for automobile batteries are 100 to 300 A.h.

As an example, a 200 A.h battery can supply a load current of 200/8 or 25A, used on 8h discharge. The battery can supply less current for a longer time or more current for a shorter time.

Automobile batteries may be rated for cold cranking power, which is related to the job of starting the motor . A typical rating is 450A for 30s at a temperature of 0 degree F.

Note that the ampere-hour unit specifies coulombs of charge. For instance, 200 A.h. corresponds to 200A*3600s (1h=3600s). the equals 720,000 A.S, or coulombs. One ampere-second is equal to one coulomb. Then the charge equals 720,000 or 7.2*10^5C. To put this much charge back into the battery would require 20 hours with a charging current of 10A.

The ratings for lead-acid batteries are given for a temperature range of 77 to 80F. Higher temperature increase the chemical reaction, but operation above 110F shortens the battery life.

Low temperatures reduce the current capacity and voltage output. The ampere-hour capacity is reduced approximately 0.75% for each decreases of 1 F below normal temperature rating. At 0F the available output is only 60 % of the ampere-hour battery rating. In cold weather, therefore, it is very important to have an automobile battery unto full charge. In addition, the electrolyte freezes more easily when diluted by water in the discharged condition.

SPECIFIC GRAVITY:

Measuring the specific gravity of the electrolyte generally checks the state of discharge for a lead-acid cell. Specific gravity is a ratio comparing the weight of a substance with the weight of a substance with the weight of water. For instance, concentrated sulfuric acid is 1.835 times as heavy as water for the same volume. Therefore, its specific gravity equals 1.835. The specific gravity of water is 1, since it is the reference.

In a fully charged automotive cell, mixture of sulfuric acid and water results in a specific gravity of 1.280 at room temperatures of 70 to 80F. as the cell discharges, more water is formed, lowering the specific gravity. When it is down to about 1.150, the cell is completely discharged.

Specific-gravity readings are taken with a battery hydrometer, such as one in figure (7). Note that the calibrated float with the specific gravity marks will rest higher in an electrolyte of higher specific gravity. The decimal point is often omitted for convenience. For example, the value of 1.220 in figure (7) is simply read twelve twenty. A hydrometer reading of 1260 to 1280 indicates full charge, approximately 12.50 are half charge, and 1150 to 1200 indicates complete discharge.

The importance of the specific gravity can be seen from the fact that the open-circuit voltage of the lead-acid cell is approximately equal to

V=Specific gravity + 0.84

For the specific gravity of 1.280, the voltage is 1.280 = 0.84 = 2.12V, as an example. These values are for a fully charged battery.

CHARGING THE LEAD-ACID BATERY:

The requirements are illustrated in figure. An external D.C. voltage source is necessary to produce current in one direction. Also, the charging voltage must be more than the battery e.m.f. Approximately 2.5 per cell are enough to over the cell e.m.f. so that the charging voltage can produce current opposite to the direction of discharge current.

Note that the reversal of current is obtained just by connecting the battery VB and charging source VG with + to + and to-, as shown in figure. The charging current is reversed because the battery effectively becomes a load resistance for VG when it higher than VB. In this example, the net voltage available to produce charging currents is 15-12=3V.

A commercial charger for automobile batteries is essentially a D.C. power supply, rectifying input from the AC power line to provide D.C. output for charging batteries.

Float charging refers to a method in which the charger and the battery are always connected to each other for supplying current to the load. In figure the charger provides current for the load and the current necessary to keep the battery fully charged. The battery here is an auxiliary source for D.C. power.

It may be of interest to note that an automobile battery is in a floating-charge circuit. The battery charger is an AC generator or alternator with rectifier diodes, driver by a belt from the motor . When you start the car, the battery supplies the cranking power. Once the motor is running, the alternator charges he battery. It is not necessary for the car to be moving. A voltage regulator is used in this system to maintain the output at approximately 13 to 15 V.The constant voltage of 24V comes from the water air panel controlled by the charge controller so for storing this energy we need a 24V battery so two 12V battery are connected in series.It is a good idea to do an equalizing charge when some cells show a variation of 0.05 specific gravity from each other. This is a long steady overcharge, bringing the battery to a gassing or bubbling state. Do not equalize sealed or gel type batteries.

With proper care, lead-acid batteries will have a long service life and work very well in almost any power system. Unfortunately, with poor treatment lead-acid battery life will be very short.

BATTERY VOLTAGE:

A 6V battery consists of 3 cells of 2V each. A 12V battery consists of 6 cells of 2V each. The cells are all similar in internal construction and operation.

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CHAPTER-3

DESIGN

Selection of motor for kinematic link vehicle This value is assumed that ,Total mass=15 kg (app.) Assume that is neglected due to motion of plates w = m*gw = 15*9.81w = 147.15Nw = Rn F = *RnF = *wF = 147.15 NT = F*rSince, r = radius of drive sprocket R=2.5cm,T= 147.15 *2.5 = 367.875 N-cmT = 3.67 N-mT = 37.5 Kg-cmAs we have to walk robot on horizontal surface , we require initially more torue & less speed. all these requirements can be fulfill by D. C. motor. As per the graphs, current is directly proportional to torque & inversely proportional to speed. hence for our kinematic link walking robot we have selected D.C. motor.

Chain sprocket Name of part Chain sprocket D=50mm, z =15, Pitch=9.525 Qty 04 Material Mild Steel

Fig 3.8 Chain sprocket

3. 1. DESIGN OF BATTERY CELL:

Power of the cell=1 WVoltage of cell=2.5 VTherefore, power of cells produced =12 WVoltage cells=19.5 VoltsCurrent produced in these cells=1A.

3. 2. DESIGN OF KYNAMATIC LINK VEHICLE STRUCTURE:The structure is made up of thin sheet metal .Structure:1. M.S. Sheet=20guage2. Diamensions=1.5 feet x 1.5 feet x 2.5 feet5. Clamping bolt=M.S.3. 3. DESIGN OF BATTERY:Current carrying capacity of 12 V battery=7.5 AHFor batteries the current=12 V / 7.5 AHThe battery discharges at a rate of 0.75. It will withstand for 10 hours.

3.4.DESIGN OF MOTOR :Engine RPM=30 RPMOperating Voltage=12vWattage=6W

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CHAPTER- COST ESTIMATION

MATERIAL COST

Sl. No.PARTICULARSMATERIALCOST (RS.)

1.main motormetal 3900/- 2.StandSheet metal (20 Gauge)1500/- 3. body1550/- 4.chain Plastic2000/- 6.DC bodyPlastic3500/- 7.Battery (12 V- 2 Nos.)Lead Acid Battery850/- 8.Miscellaneous1800/-9. BEARING 2000/-ALUMIUM LINK WITH LEGS1800/-CONTROL SWITHC PVC400/-PICK AND place arm aluminum 3000/- Total

TOTAL COST:

(1) Material Cost=RS.(2) cutting and bending Cost=RS. 830.00(3) Other expenses=RS. 400.00__________TotalRS.__________

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CHAPTER- ADVANTAGES AND APPLICATIONS

6. 1. ADVANTAGES:The advantages of kynamatic link vehicle are It is good alternative for electric powered robot . The alternative for agricultural spaying as it can move on any surface. Maintenance cost is negligible The use will be most welcomed when the power resources are over. It produses noise but working is effective . It does not create any hazerdious situations. The construction is simple and not so difficult as other blower. Simple to use and easy to manufacture. Long durability and reliability.

6.2APPLICATION:

The is mainly used for keep in move in the area where surface is un uniform and it can be used in house or in industry. the size can be changed as depending on the requirement to move on the area.

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CHAPTER-7 CONCLUSION & SUGGESTION

7. 1. CONCLUSION:

kynamatic link vehicle have been designed successfully for the village former who cannot afford multi monuvring machine for multiplie application of need,money, electricity and he can make importance of non-conventional energy resources utilization and but its use is not restricted to farmers any one can use it.

7. 2. SUGGESTION:Our kynamatic link vehicleoperating cost is almost negligible when compared to existing method of using a other devices. Though the initial cost of the project is high, both central and state government assistance in the form of subsidies for the air aided projects make job easy.

Instead of doing modification on existing body, a separate structure with less weight and separate motor may be successfully designed for thee system to have further more efficient and more economical and reduce the weight further.

---------------------------------------------------------------------------------BIBLIOGRAPHY---------------------------------------------------------------------------------

BIBLIOGRAPHY

1.AIR ENERGY-AGGARWAL2.petrol AIR ENERGY-S.K.BOSE1. PRINCIPLES OF CONVERSION OF ENERGY 2. THE HINDU DATED-27.01.1993.3. ASPEE BOLD-SUPPLEMENTRY4. AUTOMOTIVE ELECTRICAL EQUIPMENT- KOHLI

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Structure:

DESIGN

Selection of motor for kinematic link vehicle

This value is assumed that , Total mass=15 kg (app.) Assume that is neglected due to motion of plates w = m*gw = 15*9.81w = 147.15Nw = Rn F = *RnF = *wF = 147.15 NT = F*rSince, r = radius of drive sprocket R=2.5cm,T= 147.15 *2.5 = 367.875 N-cmT = 3.67 N-mT = 37.5 Kg-cm

As we have to walk robot on horizontal surface , we require initially more torue & less speed. all these requirements can be fulfill by D. C. Geared motor. As per the graphs, current is directly proportional to torque & inversely proportional to speed. Hence for our kinematic link walking robot we have selected D.C. motor.

Chain sprocket Name of part Chain sprocket D=50mm, z =15, Pitch=9.525 Qty 04 Material Mild Steel

Fig 3.8 Chain sprocket

3. 1. DESIGN OF BATTERY CELL:

Power of the cell=1 WVoltage of cell=2.5 VTherefore, power of cells produced =12 WVoltage cells=19.5 VoltsCurrent produced in these cells=1A.

3. 2. DESIGN OF KYNAMATIC LINK VEHICLE STRUCTURE:The structure is made up of thin sheet metal .Structure:1. M.S. Sheet=20guage2. Diamensions=1.5 feet x 1.5 feet x 2.5 feet5. Clamping bolt=M.S.

3. 3. DESIGN OF BATTERY:Current carrying capacity of 12 V battery=7.5 AHFor batteries the current=12 V / 7.5 AHThe battery discharges at a rate of 0.75. It will withstand for 10 hours.

3.4.DESIGN OF MOTOR :Engine RPM=30 RPMOperating Voltage=12vWattage=6W Gear Box: Metal gear

Compoent list and cost

Sl. No.PARTICULARSMATERIALCOST (RS.)

1.main motormetal12v 2 5200/- 2.StandSheet metal (20 Gauge)1500/- 3. body550/- 4.chain steel2000/- 6.DC bodymetal3500/- 7.Battery (12 V- 2 Nos.)Lead Acid Battery1750/- 8.Miscellaneous1800/-9. M.S. Rod10,mm1650/- Total

CHAPTER INTRODUCTION Material handling is a specialized activity for a modern manufacturing concern. It has been estimated that about 60-70% of the cost production is spent in material handling activities.Need for pick and place material handling:

Reduction of lab our and material cost Reduction of overall cost Increased production Increased storage capacity Increased safety Reduction in fatigue Improved personnel comfort

Literature Survey:

A ROBOT is a device which can be Reprogrammable, Multifunctional, and Sensible to Environment. Robots are limited to rolling or walking about, perhaps noting things that occur around them, but little else. The robot cant, as the slogan goes, reach out and touch someone, and it certainly cant manipulate its world.The more sophisticated robots in science, industry, and research and development have at least one robot to grasp, reorient, or move objects. Robots extend the reach of robots and make them more like humans. For all the extra capabilities arms provide a robot, its interesting that they arent at all difficult to build. Your arm designs can be used for factory style, stationary pick-and-place robots, or they can be attached to a mobile robot as an appendage. Incidentally, when we speak of arms, we will usually mean just the arm mechanism minus the hand (also called the gripper).

Take a close look at your own arms for a moment. Youll quickly notice a number of important points. First, your robots are amazingly adept mechanisms. They are capable of being maneuvered into just about any position you want. Your arm has two major joints: the shoulder and the elbow (the wrist, as far as robotics is concerned, is usually considered part of the gripper mechanism). Your shoulder can move in two planes, both up and down and back and forth. As well as moving your arm up and down and back and forth, you can rotate your shoulder as well. The elbow joint is capable of moving in one plane; it can be thought of as a simple hinge, and the bone connected to it can be rotated.The joints in your robots , and your ability to move them, are called degrees of freedom. Your shoulder provides three degrees of freedom in itself; shoulder rotation and two-plane shoulder flexion. The elbow joint adds a fourth and fifth degree of freedom: elbow flexion and elbow rotation.Robot also have degrees of freedom. But instead of muscles, tendons, ball and socket joints, and bones, robot arms are made from metal, plastic, wood, motors, solenoids, gears, pulleys, and a variety of other mechanical components. Some robot arms provide but one degree of freedom; others provide three, four, and even five separate degrees of freedom.WORKING PRINCIPLE

The experimental setup consist of three motors, all are of geared type. These robot are used where un suitable human conditions are present where human cant work in that situation that work is carried out by this robot where by remote control the operation is performed safely with out risking human life so that this robot are designed.In this robot system, a vehicle is designed to control its forward and reverse direction motion through the remote stick, this vehicle is incorporated with the moving arm.The arm is equipped by a motorized jaw to hold a small objects, the jaw is fitted on two arms, the position of this arm selectable indipendantly.the arm positioning is driven by geared direct current motors. Also the arm is based on a rotating mechanism with the help of this mechanism the complete jaw is movable to a complete 360 degree it self. The vehicle is able to run in forward and reverse direction.. Which but using wired remote control. 12V 60 RPM DC geared motor

Introduction

NR-DC-ECO is high quality low cost DC geared motor. It contains Brass gears and steel pinions to ensure longer life and better wear and tear properties. The gears are fixed on hardened steel spindles polished to a mirror finish. These spindles rotate between bronze plates which ensures silent running. The output shaft rotates in a sintered bushing. The whole assembly is covered with a plastic ring. All the bearings are permanently lubricated and therefore require no maintenance. The motor is screwed to the gear box from inside.

Specifications

Total length: 46mmMotor diameter: 36mmMotor length: 25mmDC supply: 4 to 12VRPM: 100Brush type: Precious metalGear head diameter: 37mmGear head length: 21mmOutput shaft: CenteredShaft diameter: 4mm and 6mmShaft length: 22mmGear assembly: SpurTorque: 0.25 to 7Kg/cm

HARDWARE PARTPHYSICAL MODEL

1. We have collected some hardware needed for the project which include Two geared motors of 6v/50rpm (Why only geared motor? because simple motors have very high rpm which can cause trouble in rover movement. Thus we decrease the rpm of motor by using two gears, small one connected to axle of motor and bigger one connected to small one and drives the wheels with reduced rpm of almost 50rpm motor is of 6V) Two main rear wheels (diameter 74mm, thickness 13mm/plastic wheels ) One multidirectional wheel(made of steel with a ball in bottom giving free motion to be fitted in front of rover) One battery of 6v/4.5Ah/1.35A One solid board for base Two tin clamps for holding motor on board Some screws and bolts Wires

Wheels, motors, front wheel, motor clamps and base board

STEP (a)motors

(e)Holes drolling in board to fit motor clamps

SPECIFICATIONS OF MOTOR: Weight of the motor: 1kg (approx) Operating Voltage: 12V Operating current: 0.4 A Operating power required: 12 0.4 = 4.8 W Motor Speed: 1,600 rpm. As we knows, power = 2NT/ 60 Where, N = Speed in rpm, T = Torque in N.m = weight radius. Therefore, T = Power 60 / 21600 = 0.0286 N.m. And thus, radius = 0.0286/ 19.81 = 2.91 mm. = 3 mm (say).

CHAPTER-7FABRICATION OF THE UNIT

The fabrication of unit consist of almost all the standard welding processes such as welding, fitting, assembling etc..

The unit necessitates the manufacturing of following parts.

Vertical Movable arm Horizontal Moving arem Vice Holding Tool Relay coil Frame stand

The components manufactured in process involved in manufacturing in detail in the report else. The manufacturing and assembly of this arrangement is made as rigid as possible.

VERTICAL MOVABLE BED (UPPER ARM):

Upper arm is also called as movable Bed. As the arm can move up and down, it is called as movable arm. The upper arm is connected to the frame stand. The motor is fixed on this moving bed with suitable bolt and nut arrangement.

HORIZANTAL MOVING BED (LOWER ARM):

Horizontal moving bed also called as Lower arm. As the arm can move linear it is called as movable arm. The lower arm is connected to the frame stand. The vice is fixed on this moving bed with suitable bolt and nut arrangement.

SUPPORTING JAW:

It is found on the either end of the vice which is fixed on the base plate by the help of bolt and nut. Its supports the work piece can be moved of max angle fixing the jaw the work piece to be cut is placed to an angle whose edge. Handle is rotated the self tilting jaw, when approaches the other side of the work piece automatically moves to angle and grips the work piece.FRAME STANDIt is made up of mild steel. This is the base of the above all components of the machine.

Auminium pipe

Aluminum square tubing is pretty commonly used in some areas like door or window frames, architectural features and trims, decks and porches, furniture, exercise equipment, conveyor belts, railings escalators etc. Due to the fact that this tubing has an angular shape, it becomes easy to install and transport it as it can be stacked together without their rolling off.

Use of rectangular or square tubing

A lot of set ups that manufacture equipment for automobile, industrial, agricultural and marine sectors, use this kind of tubing. Apart from the industrial usage, square or rectangular tubing is also used extensively for ornamental and decorative purposes both outdoors as well as indoors. Apart from aluminum, this kind of rectangular and square tubing is also made from transparent plastic and acrylic. These are widely used in landscaping of gardens, lighting, dance and theater events etc.

Aluminum Square TubingAluminum Square Tubing is widely used where anti corrosion, flexibility and light weight are the properties required in the materials which are being used. As we know aluminum satisfies all these properties quite well. Square and rectangular tubing made from aluminum and other materials is widely used in the manufacture of computers, in the military and aerospace industry etc. These are the places where structural strength is of great importance and this is why square or rectangular tubing is used instead of round tubing. For instance high tensile steel square or rectangular tubing is used in constructing truck and rail frames, trainer beds, and carriage frames.

Benefits of different materials

Apart from aluminum square tubing or rectangular tubing, you can find rectangular or square tubing made from materials like stainless steel, galvanized iron, cast iron, galvanized or anodized aluminum, carbon steel, copper, and even alloys like bronze. These materials can be given a great finish by polishing or coating them with metals like chromium and zinc. They are also often heat treated when the intended usage is mostly outdoors. This will prevent them from reacting to the weather, corrosion, rust etc. that normally happens with metal tubing when it is exposed to the elements. It is also necessary to conform to the industry safety standards. Materials like plastics, acrylic and PVC are used were light weight materials are required like food and beverage industry, chemical and pharmaceutical industry etc. Plastics PVC and acrylic do not corrode in the open and this is the reason why they are widely used as outdoor shelving and displays. As opposed to the metal square or rectangular tubing the one made of plastics, PVC and acrylic does not react to the harsh chemicals and solvents.

Using square or rectangular tubing

Aluminum square tubing is often joined together to create long lengths of tubing as per requirement. Usually aluminum welding is used to attach one length of tubing with another. On the other hand various methods like heat sealing, welding, adhesives or square or rectangular connectors are used to connect tubing made of other materials. Rectangular or square tubing is easier to cut and if the tubing is not very thick, you can cut it using a hand held saw or power tool even at home. The square or rectangular shape makes it quite easy to handle, operate and install.

Screw selectionScrew type: Counter sunk screws (1) Size- M3 (2) Size- M6 d = 3 mm d = 6 mm l = 10 mm l = 20 mm (3) Size- M3 (4) Size- M3 d = 3 mm d = 3 mm l = 6 mm l = 6 mm (5) Size- M5 d = 5 mm l = 20 mm

Fig 3.10 ScrewsMANUFACTURING pick and place arm4.1) PROCESS SHEET4.2) STANDARD PARTS4.1.1) FrameTable 4.1:- Main baseSr. No.MachineOperationTime(min)

1

Hacksaw machine

Cutting required pieces from plywood10

2Hand grinderdebarring10

4.1.2) armTable 4.2:- TriplateSr. No.MachineOperationTime

1Hacksaw machine

Cutting required pieces from aluminium pipe10

2Hand grinderdebarring10

3Drilling machineDrilling20

4Portable GrinderGrinding5

4.1.3) jaw

Table 4.3:- Sr. No.MachineOperationTime

1Hacksaw machine

Cutting required pieces from aluminium pipe10

2Hand grinderdebarring10

3Drilling machineDrilling20

4Portable GrinderGrinding5

1Hacksaw machine

Cutting required pieces from aluminium pipe10

4.1.4) fitting AND ASSEMBLY

Table 4.4Sr. No.MachineOperationTime

1Hacksaw machineCutting from saw stock5

2DRILLING MACHINEDRILLING10

4SCREW DRIVESCREWING AND FITTING20

Chapter 1: LITERATURE SURVEY1.1 ROBOTICSThe word Robotics, meaning the study of robots was coined by Isaac Asimov. Robotics involves elements of both mechanical and electrical engineering, as well as control theory, computing and now artificial intelligence (Selig, 1992). According to the Robot Institute of America, A robot is a reprogrammable, multifunctional manipulator designed to move materials, parts, tools or specialized devices through variable programmed motions for the performance of a variety of tasks(Robotics Research Group, n.d.) The fact that a robot can be reprogrammed is important: it is definitely a characteristic of robots. In order to perform any useful task the robot must interface with the environment, which may comprise feeding devices, other robots, and most importantly people.

1.2 ROBOTIC ARMRobots without arms are limited to rolling or walking about, perhaps noting things that occur around them, but little else. The robot cant, as the slogan goes, reach out and touch someone, and it certainly cant manipulate its world.The more sophisticated robots in science, industry, and research and development have at least one arm to grasp, reorient, or move objects. Arms extend the reach of robots and make them more like humans. For all the extra capabilities arms provide a robot, its interesting that they arent at all difficult to build. Your arm designs can be used for factory style, stationary pick-and-place robots, or they can be attached to a mobile robot as an appendage. Incidentally, when we speak of arms, we will usually mean just the arm mechanism minus the hand (also called the gripper).

1.2.1 The Human ArmTake a close look at your own arms for a moment. Youll quickly notice a number of important points. First, your arms are amazingly adept mechanisms. They are capable of being maneuvered into just about any position you want. Your arm has two major joints: the shoulder and the elbow (the wrist, as far as robotics is concerned, is usually considered part of the gripper mechanism). Your shoulder can move in two planes, both up and down and back and forth. As well as moving your arm up and down and back and forth, you can rotate your shoulder as well. The elbow joint is capable of moving in one plane; it can be thought of as a simple hinge, and the bone connected to it can be rotated.The joints in your arm, and your ability to move them, are called degrees of freedom. Your shoulder provides three degrees of freedom in itself; shoulder rotation and two-plane shoulder flexion. The elbow joint adds a fourth and fifth degree of freedom: elbow flexion and elbow rotation.Robotic arms also have degrees of freedom. But instead of muscles, tendons, ball and socket joints, and bones, robot arms are made from metal, plastic, wood, motors, solenoids, gears, pulleys, and a variety of other mechanical components. Some robot arms provide but one degree of freedom; others provide three, four, and even five separate degrees of freedom.

1.2.2 Arm TypesRobot arms are classified by the shape of the area that the end of the arm (where the gripper is) can reach. This accessible area is called the work envelope. For simplicitys sake, the work envelope does not take into consideration motion by the robots body, just the arm mechanics.The human arm has a nearly spherical work envelope. We can reach just about anything, as long as it is within arms length, within the inside of about three-quarters of a sphere. Imagine being inside a hollowed-out orange. You stand by one edge. When you reach out you can touch the inside walls of about three-quarters of the peel. In a robot, such a robot arm would be said to have revolute coordinates. The three other main robot arm designs are polar coordinate, cylindrical coordinate, and Cartesian coordinate. Youll note that there are three degrees of freedom in all four basic types of arm designs.

1.2.2.1 REVOLUTE COORDINATERevolute coordinate arms, such as the one depicted in Fig.1, are modelled after the human arm, so they have many of the same capabilities. The typical robotic design is somewhat different, however, because of the complexity of the human shoulder joint. The shoulder joint of the robotic arm is really two different mechanisms. Shoulder rotation is accomplished by spinning the arm at its base, almost as if the arm were mounted on a record player turntable.

Fig.1.1:- A revolute coordinate arm

Shoulder flexion is accomplished by tilting the upper arm member backward and forward. Elbow flexion works just as it does in the human arm. It moves the forearm up and down. Revolute coordinate arms are a favourite design choice for hobby robots. They provide a great deal of flexibility, and they actually look like arms.

1.2.2.2 POLAR COORDINATEThe work envelope of the polar coordinate arm is the shape of a half sphere. Next to the revolute coordinate design, polar coordinate arms are the most flexible in terms of the ability to grasp a variety of objects scattered about the robot. Fig. 2 shows a polar coordinate arm and its various degrees of freedom. A turntable rotates the entire arm, just as it does in a revolute coordinate arm. This function is akin to shoulder rotation. The polar coordinate arm lacks a means for flexing or bending its shoulder, however. The second degree of freedom is the elbow joint, which moves the forearm up and down. The third degree of freedom is accomplished by varying the reach of the forearm. An inner forearm extends or retracts to bring the gripper closer to or farther away from the robot. Without the inner forearm, the arm would only be able to grasp objects laid out in a finite two-dimensional circle in front of it.

Fig. 1.2:- A polar coordinate arm.

The polar coordinate arm is often used in factory robots and finds its greatest application as a stationary device. It can, however, be mounted to a mobile robot for increased flexibility.

1.2.2.3 CYLINDRICAL COORDINATEThe cylindrical coordinate arm looks a little like a robotic forklift. Its work envelope resembles a thick cylinder, hence its name. Shoulder rotation is accomplished by a revolving base, as in revolute and polar coordinate arms. The forearm is attached to an elevator like lift mechanism, as depicted in Fig. 3. The forearm moves up and down this column to grasp objects at various heights. To allow the arm to reach objects in three-dimensional space, the forearm is outfitted with an extension mechanism, similar to the one found in a polar coordinate arm.

Fig. 1.3:- A cylindrical coordinate arm

1.2.2.4 CARTESIAN COORDINATEThe work envelope of a Cartesian coordinate arm (Fig. 4) resembles a box. It is the arm most unlike the human arm and least resembles the other three arm types. It has no rotating parts. The base consists of a conveyer belt-like track. The track moves the elevator column (like the one in a cylindrical coordinate arm) back and forth. The forearm moves up and down the column and has an inner arm that extends the reach closer to or farther away from the robot.

Fig.1.4:- A Cartesian coordinate arm

1.3 Activation TechniquesThere are three general ways to move the joints in a robot arm: Electrical Hydraulic PneumaticElectrical actuation is done with motors, solenoids, and other electromechanical devices. It is the most common and easiest to implement. The motors for elbow flexion, as well as the motors for the gripper mechanism, can be placed in or near the base. Cables, chains, or belts connect the motors to the joints they serve. Electrical activation doesnt always have to be via an electromechanical device such as a motor or solenoid. Other types of electrically induced activation are possible using a variety of techniques. One of particular interest to hobby robot builders is shape-memory alloy, or SMA, as discussed previously.Hydraulic actuation uses oil-reservoir pressure cylinders, similar to the kind used in earthmoving equipment and automobile brake systems. The fluid is noncorrosive and inhibits rust: both are the immediate ruin of any hydraulic system. Though water can be used in a hydraulic system, if the parts are made of metal they will no doubt eventually suffer from rust, corrosion, or damage by water deposits. For a simple home-brew robot, however, a water-based hydraulic system using plastic parts is a viable alternative.Pneumatic actuation is similar to hydraulic, except that pressurized air is used instead of oil or fluid (the air often has a small amount of oil mixed in it for lubrication purposes). Both hydraulic and pneumatic systems provide greater power than electrical actuation, but they are more difficult to use. In addition to the actuation cylinders themselves, such as the one shown in Fig. 26-5, a pump is required to pressurize the air or oil, and values are used to control the retraction or extension of the cylinders. For the best results, you need a holding tank to stabilize the pressurization. For small robot arms, the Lego Techniques pneumatic cylinders, controls, and tanks can make the task of actuating an arm quite easy.An interesting variation on pneumatic actuation is the Air Muscle, an ingenious combination of a small rubber tube and black plastic mesh. The rubber tube acts as an expandable bladder, and the plastic mesh forces the tube to inflate in a controllable manner. Air Muscle is available premade in various sizes; it is activated by pumping air into the tube. When filled with air, the tube expands its width but contracts its length (by 25 percent). The result is that the tube and mesh act as a kind of mechanical muscle. The Air Muscle is said to be more efficient than the standard pneumatic cylinder, and according to its makers it has about a 400:1 power-to-weight ratio.Our project is a Polar Coordinate robotic arm having fixed length and Electrical activation to reduce the overall cost.

Types of Robots and Robotic technique:The project chosen by us that is spy Robotics stands on our area of interest.This project combines the feature of both wireless communication and microcontroller. This project comprises of the outstanding features of being wireless which means freedom from being restricted to an area of particular frequency.Its another robot with a cutesy name, SPYKE the Wi-Fi Spy Robot. Its due to be sold under the Meccano brand name which is pretty appropriate as well have to make him your self. Once constructed itll be able to control Spyke from any Internet enabled PC, It incorporates VOIP and a web-cam so youll be able to send him on dangerous spying missions and watch the results from the other side of the world. When SPYKE is running low on robot juice itll use its auto parking system to dock with his recharging system.The spy robots constructed by us has control system based on 8051 microprocessor. Though DSP chips can be used for the same but same but due to the extra benefit of microprocessors chips; they are preferred here. The primary advantage that these processors provide is their speed. They can perform simple operations with blinding speed, and so complete great amounts of work.DSP chips are basically special-purpose processors designed to serve a particular class of computational problems. The central feature common to most DSP chips is a MAC, which stands for Multiply and Accumulate. DSP processors are often used to process continuous streams of information such as audio, video, or data from an RF receiver. The data stream never stops and must be processed at all times. This is its biggest advantage as well as the disadvantage too.

Not surprisingly, the best choice for the robot is the microcontroller based control system. Modern microprocessors that we could use in our robot range between 8- and 64-bit word sizes. The 8-bit computers are generally well suited for most simple robot calculations and control system loops. Most robot designs have 8-bit processors to save power and money.

2.1 Robot Design

There are a number of other considerations to take into account when designing a robot. Thus far in our calculations and mathematics, weve assumed that all control elements behave in a linear fashion. Very roughly defined, this assumes a smooth, continuous action with no jerky motions. Bringing in a definition from calculus, this linear motion is characterized by curves with finite derivatives. For the moment sending our robot over the terrain described by each curve and it will be easy to visualize why we should be considering nonlinear control elements. We must be prepared to deal with such matters because most robots have some nonlinear elements somewhere within the design.